ORBIS Product Cost Calculator. 100% SAP-Integrated Calculation flexible and simplified

Transcription

1 ORBIS Product Cost Calculator 100% SAP-Integrated Calculation flexible and simplified

2 Optimal calculation in SAP with ORBIS Product Cost Calculator (ORBIS PCC) Only companies that accurately calculate their product and manufacturing costs and quotations, also across departments, and have a complete overview thereof - from construction, sales to controlling will be economically successful for the long term. The more precise the cost estimate, the more sound the decision-making bases are, ensuring a forward-looking and efficient control of the company. SAP ERP must be the system that achieves these goals. Although a large number of manufacturing companies already use SAP ERP for the planning and managing of their business processes, in most cases, production costs (material prices, hourly rates, tariffs etc.) are calculated and simulated in external solutions such as Microsoft Excel or Access. As these calculations are generated decentralized, i.e. outside of SAP, neither data flows nor calculation histories can be reproduced. A further disadvantage is the high error rate and the enormous maintenance effort in terms of time, as the calculation data constantly need to be manually copied or transferred between SAP and Excel and updated. This problem is exacerbated for complex products or products involving a large number of variants. Product cost calculation without redundant data storage directly in SAP with ORBIS PCC The ORBIS Product Cost Calculator (ORBIS PCC), an SAP add-on based on ABAP, enables calculation directly in SAP, across accounting and cost accounting areas with a uniform calculation scheme. The online access to current controlling and production data as well as purchasing and sales terms, which is maintained centrally in SAP, makes it possible to accurately and quickly calculate product and manufacturing costs, from the construction to the quotation phase. Wage labor or external work processes are also considered. ORBIS PCC extends SAP Standard: With ORBIS PCC, all calculation phases are located 100% in SAP SAP is the main system. Production cost calculation with ORBIS PCC directly in SAP with or without master data Non-SAP Master Data ORBIS PCC as Integrator for Pricing Processes CAD/ PLM Product Catalog Excel Offer Config. Tool Bill of Materials Any external formats SAP Master Data and Processes Pricing during the development stage Manufacturing cost pricing plus Offer Pricing Material Master Production Technology PP MM SD CO 2

3 Processes supported with ORBIS PCC The ORBIS Product Cost Calculator optimally supports the following application areas for the determination of manufacturing costs: 1. Construction and development cost calculation When developing new products, cost estimators often need to work with calculation items for which neither master data exist in the SAP system, nor prices are known for. With ORBIS Product Cost Calculator new materials or assemblies, for which no material numbers nor purchase prices are yet entered in the SAP systems, can be created with a price and a short text. These materials or assemblies which are not available in SAP, can be generated and created as new SAP master data via a function integrated into the add-on, when an order is placed. The ORBIS Product Cost Calculator estimates materials with pre-set calculation variants and calculation procedures. Prices can also be manually adjusted in the calculation: All changes are fully documented and thus reproducible at all times. No master data are created yet, however, the calculation is performed in SAP. The cost type can be assigned here, in order to manage the associated overhead costs. Non-SAP Master Data ORBIS PCC as Integrator for Pricing Processes SAP Master Data and Processes Non-SAP master data can become SAP master data. CAD/ PLM Product Catalog Pricing during the development stage Material Master BOM items Excel Production Technology Offer Config. Tool Manufacturing cost pricing plus Estimates/quotation prices Target costs Work processes Supplementary information (Attach text, documents) Bill of Materials PP MM SD Status information (maturity level) Dummy materials Any external formats Offer Pricing CO 2. Manufacturing cost calculation Plus Compared to standard material cost calculations, additional cost elements (e.g. tool costs) can be added in the manufacturing cost calculation Plus in the form of surcharges and variable items. It is possible to both simulate and change a material calculation, as well as to compare different calculations. Also, calculations with the same contents can be performed and saved with different calculation variants. Separate surcharges or variable items are added. Non-SAP Master Data ORBIS PCC as Integrator for Pricing Processes SAP Master Data and Processes CAD/ PLM Product Catalog Pricing during the development stage Material Master Excel Production Technology Offer Config. Tool Manufacturing cost pricing plus Bill of Materials PP MM SD Any external formats Offer Pricing CO Overhead costs Variable costs Different batch sizes Tool surcharges Special production costs Project costs 3

4 Processes supported with ORBIS PCC 3. Cost calculation Individual or special manufacturers often create extensive quotations, which need to be changed often or recalculated, before the customer places the order. However, only a small number of quotations actually results in orders. To avoid creating and maintaining unnecessary master data, ORBIS Product Cost Calculator allows calculations with dummy master data (materials, work schedules, assemblies). The cost estimate can be transferred into an SD offer without media break. All terms saved in the customer master data (e.g. discounts, commissions, freight costs etc.) can be reused. No master data need to be created. In this case, quantity-based purchase terms are applied. The cost estimate can be calculated based on a request and transferred into an SD offer. Non-SAP Master Data ORBIS PCC as Integrator for Pricing Processes SAP Master Data and Processes Non-SAP master data can become SAP master data CAD/ PLM Product Catalog Pricing during the development stage Material Master Profit mark-ups Special sales costs Customer terms Scaled quantities Variants Excel Production Technology Offer Config. Tool Manufacturing cost pricing plus ORBIS PCC calculation surcharges Bill of Materials PP MM SD Any external formats Offer Pricing CO SAP ORBIS PCC Efficient calculating based on consistent process integration ORBIS PCC ORBIS PCC ORBIS PCC Request Pricing Offer Order Production Delivery Automatic SD Offer - System Automatic master data generation Post-order Calculation: Actual/Target Comparison (optional) With ORBIS PCC, all pricing phases are completed 100% in SAP. Therefore, processes for product development/production, purchasing, sales and controlling are supported optimally. SAP is the leading system. 4

5 ORBIS PCC: A crucial added value for calculation in SAP Functional highlights of ORBIS PCC Calculation and simulation exclusively in SAP (PP, CO, MM, SD, PS) Calculation and simulation across cost estimate and accounting areas Calculation with and without SAP master data Calculation and simulation of a complete product cost lifecycle Generation of calculations without templates or based on document structures, sales receipts, sales materials, work schedules etc. Creation of calculation templates Creation of calculations and processing by means of context menus (right mouse button), graphic elements (colors, icons) and copy tools Define own surcharges (in percentage, as a fixed value, formula) Calculation versions (max. 99) and calculation comparisons Extensive search tools, change history and error list Individually adjustable status system (maturity) on calculation level Automatic quotation generation in SAP SD Integration into SAP variant configuration Customer-specific extensions or integration of external data sources at any time through SAP User Exits and BADIs Automatic creation of SAP master data Optionally, calculation with external data from PLM or CAD systems, material catalogs, machining times calculators, cycle time calculators Extended functions Integration for cost / benchmark databases Calculation of machine hourly rates, processing operations and material prices according to countries and regions (to be selected) Long-term project calculations Work flow-supported calculation processing and generation of cost estimates Advantages and benefits of ORBIS PCC Advantages for calculation processes Up-to-date, accurate calculation data and quick creation and simulation of calculations through real-time integration into the existing SAP ERP system Low maintenance, as existing ERP data are accessed from almost all SAP modules: integrated data models, therefore no data redundancy Quick retrieval of calculations (centrally stored in SAP, various search functions) Uniform central calculation with or without master data in SAP Intuitive and user-friendly operation Quick creation and processing of calculations with calculation templates Cost and process transparency across product cost life cycles, tools and country borders for quick and sound management decisions Efficient calculating based on consistent process integration (e.g. request - cost estimate - order) and avoidance of media breaks Efficient make-or-buy decisions through market and supplier analyses based on average, global material, machine and labor costs Advantages through SAP technology or integration SAP basis technology: existing company SAP / IT resources can be used Users already work with SAP and can immediately create calculations without extensive training requirements No further investments into additional infrastructures (server, database) required Reduction of number of interfaces, systems and potential sources of error Investment protection: own SAP name space; ORBIS PCC can be extended through standardized SAP interfaces at any time Reduction of process costs through automated generation of master data 5

6 Intuitive operation and functionalities... New calculations can be accessed via different channels (e.g. via master data or sales receipts). A new calculation can be started or a completed calculation can be used as the basis for a modified calculation. The following actions can be initiated via a context menu (right mouse button): Change, delete or insert items. An error list is displayed and explained. Parts from a multi-level specified BOM list (material or calculation) can be copied and inserted into other calculations. Easy copying or moving of individual items with drag & drop function. Items/elements can be copied and inserted at a different location. Intuitive operation through visual support (graphic symbols and colors). Complete access to all information in all SAP tables possible. Calculation across accounting and cost accounting areas. Construction data / CAD data can be read into ORBIS PCC. 6

7 ... simply the calculation in SAP 99 different calculation versions possible. Depending on the desired scaled quantities, a quantity-based calculation version is created for each calculation batch size. Comparison of multiple calculations possible (e.g. for the visualization of different manufacturing alternatives). Documents can be integrated (e.g. external quotations or own notes on certain items). Calculation with or without master data with dummy materials (insertion of fictitious materials). Data maintenance only centrally in SAP. SAP is the main system. Change history automatically logged: Changes per calculation item can be displayed individually. Additional module allows for calculation over several years. 7

8 Example: Calculations and simulations... 1 Pre-assembly I: A new process is added to the calculation via the workplace selection. 2 Housing: A new component is added via the context menu. *... Ä.. Material B... Ma... Pump, demo, new Provision according to picking list 1 Pressing of impeller into housing 2 Paint shop 3 1 Pre-assembly I 5 Installation of shaft into housing 8 Final assembly of pump 9 Delivery to warehouse 10 2 Housing 12 Turning housing according to drawing 1 Drilling openings 2 Assembly III 3 Wage hours 14 Machine hours 15 Wage hours 16 Inspection and delivery to warehouse 4 Blank for spiral housing 5 R F ROH Flat seal 6 R F ROH 3 Hexagon screw 7 R F ROH Additional costs 20 4 New test material 21 Overhead costs, raw material (10.00%) 22 Overhead costs, administration (20.00%) 23 Overhead costs, sales (15.00%) 24 Drive 13 Shaft 14 Electronics 15 Warehouse 16 Aluminum lid 17 AS-200 X Sheet metal 18 R F HALF M10 hexagon screw 19 R F ROH Tool 20 ROH Overhead costs, raw material (10.00%) 39 Overhead costs, administration (20.00%) 40 Overhead costs, sales (15.00%) 41 3 Additional costs: Unforeseen additional costs can be specified directly in the calculation. 8

9 ... easy with ORBIS PCC in SAP... Cost accounting area 1000 PG Language German Sample calculation Quan... E Total Quantity Total Value 1,500 PC 1,500 1,197, , , , , , , , PC 1, , , , , H 0 0 H H 125 5, , PC 1,500 7, PC 1,500 34, PC 12,000 1, , PC 7, , , Status Order ORBIS webinar User AREKLA AREKLA Request Valid from Valid until Quotation Customer HSA Netsolution VertrBer Description Pump, demo, new Sale office 1000 Sales group 100 Plant 1000 Config. Material Material type SM calc. Surcharge MKalkGrp FERT PKK_KMAT_ST FERT COGS SAP10 5 Sum. Menge Sum. Wert , , , , , , , , ,06 New total value of the calculation Quantity change in calculation: The price date and calculation quantity can be changed at any time. 1 PC 1,500 85, PC 1, , PC 1,500 17, PC 1,500 15, PC 9,000 69, M2 7, PC 15,000 7, PC 1, , , New 153, test material: A new material component, without SAP master data set, was created. 9

10 Outlook: ORBIS PCC functionality Long-term project calculation The special feature of the project calculation is the spreading of project costs over several years, taking into account both inflation and cost increase factors (e.g. labor costs, material prices, raw material prices etc.) as well as cost savings potentials demanded by customers. This is made possible through the definition and creation of milestones, own surcharges etc. in ORBIS PCC. Wage rates and purchase prices can be escalated over the total term. Any time-dependent surcharge factors can be mapped. Milestones can be defined and evaluated on an individual basis. Special feature for orders/tenders by industrial companies for the public sector: ORBIS PCC allows for the creation of auditable tender documents taking into account the statutory guidelines for pricing review and pricing law. Use of benchmark data Within a manufacturing cost calculation, a comparison of global location factors via an external cost comparison data base integrated into ORBIS PCC is possible. This allows companies to better analyze and compare supplier offers, enabling them to specify sound cost specifications for future supplier relationships, already from the start. Instead of accessing existing SAP master data, calculations can be simulated with external comparative data: average costs of materials, machines (run-times), wages and energy cost from over 60 countries can be imported into the ORBIS calculation. This comparison database contains about 240,000 data entries, 30,000 different process and benchmark costs for parts and systems as well as more than 60 country-specific data. The data base is updated every 3 months. Own entries can be added individually to the tables from the benchmark database. Analyses with Crystal Reports In field of Business Intelligence (BI), SAP offers market-leading solutions. Crystal Reports is a flexible SAP reporting tool with excellent layout functions for professional reporting, which can be used flexibly with different types of data sources. ORBIS AG develops customer-specific Crystal Report reports which contain the customer data from an OR- BIS PCC interface. These reports are directly displayed on the SAP GUI (Graphical User Interface) and can be called up directly from a calculation. The individual reports are stored on the SAP ECC Netweaver server. The customer s corporate design/layout can be fully mapped. 10

11 Conveniently calculate in SAP in just a few days The introduction of ORBIS PCC is quick and easy and only takes 3 steps: ment is now required, the ORBIS PCC application can now be taken over into the production system ORBIS supplies the ORBIS PCC transaction as a transport order, which is exported from the customer s IT into an SAP test or quality system. In coordination with the customer, customizing / parameterization settings are configured in SAP Standard (CO, SD) and In ORBIS PCC, and the standard functions and processes are implemented and tested. This is followed by the initial training of the key users. If no additional customer-specific additional develop- This means, a project can be realized in one to three months. Technical information: No additional infrastructure required 100% integrated into SAP as an SAP add-on (exclusively developed in ABAP) Own globally protected namespace avoids conflicts with SAP ERP Standard SAP release ECC 6.0 and higher Project days depending on the project requirements Implementation Go Live Support Installation and Basic Customization Implementation of Standard Functions Key User Training Support Test installation: ORBIS offers potential customers the option of testing ORBIS PCC on their own SAP test or Sandbox system. One requirement for this is a copy of the SAP productive systems, which his max. 6 to 12 months old. Another requirement is the participation in a two-day intensive test workshop, where pre-defined calculation processes are run through and tested. Before the start of the workshop, the necessary parameter settings are performed in ORBIS PCC, necessary master data are created and the SAP test system is adjusted accordingly. Following the workshop, ORBIS PCC is available for an extensive 4-week trial phase, which is guided by ORBIS on all levels. EXCERPT OF OUR REFERENCES 11

12 About us ORBIS is a business consulting company with international operations. ORBIS supports and provides consulting services for international Group companies and small and mid-sized businesses from IT strategies, system selection, and optimization of business processes to system implementation and system integration. ORBIS uses solutions from the market leaders SAP and Microsoft, companies that ORBIS shares a close partnership with. Our core competencies cover classic Enterprise Resource Planning (ERP), Supply Chain Management (SCM), Logistics Execution (EWM/LES), Manufacturing Execution Systems (MES), Variant Management, Customer Relationship Management (CRM), On-Premise and Cloud, Business Analytics (BI, EPM and data warehousing) and Product Lifecycle Management (PLM). ORBIS supports worldwide rollouts of ERP solutions and processes as a reliable partner. Own solutions for Industry 4.0, BI, MES, product costing and variant management as well as addons based on SAP complete our service portfolio. On the Microsoft Dynamics CRM platform, ORBIS offers numerous sector solutions and best practices that it has developed itself, such as SAP-integration. Over 1500 successfully completed client projects are testimony to our many years of experience in the automotive supplier industry, construction supplier industry, electrical and electronics industry, machinery and plant manufacture, logistics, metal industry, consumer goods industry, trade, financial service providers, and the pharmaceutical industry. ORBIS long-standing customer base includes among others, Bosch, Eberspächer, Edscha, Hager Group, Heineken Switzerland, Hörmann, hülsta, HYDAC INTERNATIONAL, Jungheinrich, KSB, KUKA Roboter, Magna, Melitta Haushaltsprodukte, Modine, Paul Hartmann, Pilz, Rittal, Schott, SCHUNK, Villeroy & Boch, WAGO Kontakttechnik and the ZF Group. ORBIS AG, Nell-Breuning-Allee 3-5, Saarbrücken, Germany Tel.: +49 (0) 681 / , Fax: +49 (0) 681 / , info@orbis.de, Germany w France w Switzerland w Austria w USA w China